2026/07/23
The fermentation stage marks the beginning of the production line. The double-screw turner utilizes a dual-shaft counter-rotating mechanism, capable of turning material to a depth of 1.6 meters and a width of 12 meters. The powerful mixing action of the double screws maintains the pile temperature within the ideal fermentation range of 55°C to 70°C. Chain-plate turners and large-wheel turners are suited for trough-style and windrow-style fermentation scenarios, respectively, making them particularly ideal for large-scale organic fertilizer plants and centralized manure treatment centers. Even after thorough fermentation and decomposition, the material retains a moisture content of 25% to 55% and contains significant fibrous matter and clumps.
At this stage, the half-wet material crusher serves as the critical link between fermentation and granulation. The machine features a dual-stage rotor design operating in series: material first enters the upper rotor's crushing zone, where it undergoes preliminary breakage from high-speed hammer impacts; it is then propelled into the lower rotor's crushing zone for further pulverization. Simultaneously, particles collide and grind against each other at high speeds within the chamber, achieving a dual crushing effect—"hammer-on-material" and "material-on-material." Designed without a bottom screen or mesh, the machine fundamentally resolves common industry issues such as clogging and material adhesion to the walls caused by wet materials. The pulverized material enters a horizontal mixer or a twin-shaft organic fertilizer mixer for uniform blending, ensuring a feedstock with consistent structural properties for the subsequent granulation stage.
The granulation process offers the widest variety of equipment options. The double-roller extrusion granulator (also known as a fertilizer roller press) employs a dry extrusion process; dry material is compacted into dense sheets under high pressure, which are subsequently crushed and screened into granules. The production line comprises a mixer, the double-roller extrusion granulator, a feeder, a rotary screen, and an electronic quantitative packaging scale, utilizing a room-temperature, drying-free process that achieves forming in a single pass. The disc granulator (or organic fertilizer disc granulator) features an integrated arc-shaped structure and achieves a granulation rate exceeding 93%. With adjustable disc inclination and rotation speed, it enables precise control for room-temperature granulation, ensuring that the activity of functional bacteria is not compromised by high temperatures. The new "two-in-one" organic fertilizer granulator represents a trend toward equipment integration, utilizing a synergistic "crush-then-granulate" mode; half-wet fermented material entering the inlet is first pulverized by a high-speed rotor before passing directly into the granulation chamber for shaping. Irregular granules produced in this way undergo further processing in an organic fertilizer ball shaping machine (or spheroidizing machine). Driven by the rotating disc, the granules are subjected to centrifugal and frictional forces, moving in a twisting, reciprocating pattern along the chamber wall; after multi-stage rounding, they emerge as uniform, glossy, spherical granules. Thus, the organic fertilizer granulation system completes the full transformation from powdered material to high-quality spherical granules.
In the finished product formulation stage, multi-bin/single-scale static batching systems and BB fertilizer (bulk blend) mixing lines handle precise formula blending. The BB fertilizer line consists of raw material storage and conveying systems, dynamic batching and metering systems, an NPK mixer, and an automated packaging system. Meanwhile, the production process for phosphate-based fertilizers involves the acidulation, neutralization, and granulation of phosphate rock powder, requiring specialized reaction and drying equipment. From the deep turning action of fermentation turners and the fine pulverization of half-wet material crushers to dry-method forming via double-roller extrusion granulators, wet-method pelletizing using disc granulators, the integrated one-step processing of new two-in-one organic fertilizer granulators, and granule shaping by organic fertilizer rounders—culminating in the precise blending found in BB fertilizer production lines—this comprehensive equipment lineup offers systematic solutions tailored to enterprises with varying raw material characteristics and production scales.
